(12)
`
`United States Patent
`Peng
`
`(10) Patent No.:
`(45) Date of Patent:
`
`US 7,159,368 B2
`Jan. 9, 2007
`
`US007 1593.68B2
`
`(54) PANELIZED WALL SYSTEM UTILIZING
`JOINT TAPE
`
`(75) Inventor: Weiling Peng, Alta Loma, CA (US)
`(73) Assignee: James Hardie International Finance
`B.V., Amsterdam (NL)
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 0 days.
`(21) Appl. No.: 10/306,914
`
`(*) Notice:
`
`s
`
`(22) Filed:
`
`Nov. 27, 2002
`
`- 44
`
`WallSC al. . . . . . . . . . . . . . . . . . .
`
`
`
`3,859,766 A *
`1/1975 Flotow et al. ................ 52,268
`3,977.465 A
`8, 1976 Tank
`4.450,022 A
`5/1984 Galer
`2.5 A ck g
`Eichstet al. ......... 4.5
`4,549,653 A 10/1985 Lauritzen
`639. A
`24 yah et al.
`e
`6, 1989 Weber et al. ............... 428,172
`4,837,070 A
`4.915,758 A
`4, 1990 St. et al.
`5,295,339 A
`3, 1994 Manner
`5,333,433 A * 8/1994 Porambo et al. .............. 52/417
`5,465,547 A 11, 1995 Jakel
`(Continued)
`FOREIGN PATENT DOCUMENTS
`
`(65)
`
`Prior Publication Data
`US 2004/0211139 A1
`Oct. 28, 2004
`
`DE
`
`37 33 248
`2, 1989
`(Continued)
`
`Related U.S. Application Data
`(60) Provisional application No. 60/334,144, filed on Nov.
`28, 2001, provisional application No. 60/334,138,
`filed on Nov. 28, 2001, provisional application No.
`60/333,967, filed on Nov. 28, 2001.
`(51) Int. Cl.
`(2006.01)
`Et)4B I/62
`(2006.01)
`E4F 5/4
`(2006.01)
`E04F 5/22
`(52) U.S. Cl. ............................ 52/393; 52/459; 52/460;
`52/.461; 52/471; 156/71; 156/574
`(58) Field of Classification Search ............., 52/393,
`52/481.1, 459, 460, 461, 471; 156/71, 574,
`156/577
`See application file for complete search history.
`References Cited
`
`(56)
`
`U.S. PATENT DOCUMENTS
`
`1,357,350 A 11/1920 Schumacher
`2,017,266 A * 10/1935 Walper ...................... 52.483.1
`2,078,049 A
`4, 1937 Benedict
`
`OTHER PUBLICATIONS
`Building
`Products
`http://web.archive.org/web/
`Landmark
`200208.9154015.http:www.landmark-products.com
`multicoat multitex.html.
`
`(Continued)
`Primary Examiner Amy J. Sterling
`(74) Attorney, Agent, or Firm Gardere Wynne Sewell, LLP
`
`ABSTRACT
`(57)
`Disclosed herein are panelized wall systems and methods for
`their construction, wherein the wall systems have elasto
`meric joints that are resistant to cracking. The walls are
`constructed with an elastomeric joint tape. The joint tape is
`made from an elastomeric backing material with an adhesive
`applied to a face, and optionally, a release liner laminated to
`the adhesive. In use, building panels are fastened to a frame
`gp
`with the edges adjacent to each other. The joint tape is
`applied to the seam between the panels and the wall is then
`finished with an elastomeric finish.
`
`40 Claims, 30 Drawing Sheets
`
`1
`
`4/o
`
`422
`
`452
`
`Louisiana-Pacific Corporation, Exhibit 1054
`IPR of U.S. Pat. No. 8,474,197
`Page 1
`
`

`

`US 7,159,368 B2
`Page 2
`
`U.S. PATENT DOCUMENTS
`
`5,512,612
`5,547,743
`5,691,029
`5,711,124
`5,732,520
`5,857,730
`5,891,282
`5,895,536
`5,932,646
`5,962,089
`5,966,885
`6,179,201
`6,226,946
`6,516,580
`6,745,531
`6,880,304
`2001/0028943
`2001.0034984
`2002/0146953
`2003/0O29.108
`2003, OO684.57
`2003/O126817
`
`ck
`
`4, 1996
`8, 1996
`11, 1997
`1, 1998
`3, 1998
`1, 1999
`4, 1999
`4, 1999
`8, 1999
`10, 1999
`10, 1999
`1, 2001
`5, 2001
`2, 2003
`6, 2004
`4, 2005
`10, 2001
`11, 2001
`10, 2002
`2, 2003
`4, 2003
`T/2003
`
`Brown et al. ............... 523,218
`Rumiesz, Jr. et al.
`Lucas . . . . . . . . . . . . . . . . . . . . . . . . . 428,107
`Stough et al.
`Maietta ..................... 52.483.1
`Korpi et al.
`Stough et al. ................ 156,71
`Starr et al.
`Roberts ...................... 524,476
`Jones et al.
`Chatelain
`Chess
`Stough et al.
`Maietta
`Egan ......................... 52/302.1
`Budge ...........
`52.426
`Mashiko et al. ............ 428,195
`Murphy et al.
`Lubker, II
`Neuhaus et al. ......... 52,309.12
`McCain
`Gleeson et al................ 52/460
`
`
`
`2003/O126822 A1* 7/2003 Gleeson ....................... 52/604
`2003/0.131550 A1* 7/2003 Cole et al. ............... 52,396.04
`2003/0216097 A1 11/2003 Schmid
`
`FOREIGN PATENT DOCUMENTS
`
`DE
`EP
`EP
`FR
`GB
`TW
`TW
`
`3, 1998
`297 18716
`9/1995
`O 673 657 A1
`O 683 216 Al 11/1995
`2764032
`12/1998
`2353249
`2, 2001
`77107.188
`1Of 1977
`88220820
`12, 1988
`
`.................... 15, 58
`........................ 7/2
`
`OTHER PUBLICATIONS
`
`Pat Abs. JP 2000064465, Joint Structure Between Inner Wall Panels,
`Misawa Ceramics (Feb. 2, 2000).
`Office Action mailed Feb. 24, 2004 for U.S. Appl. No. 10/306,920,
`filed Nov. 27, 2002.
`Office Action mailed Aug. 22, 2003 for U.S. Appl. No. 10/306,920,
`filed Nov. 27, 2002.
`* cited by examiner
`
`Louisiana-Pacific Corporation, Exhibit 1054
`IPR of U.S. Pat. No. 8,474,197
`Page 2
`
`

`

`U.S. Patent
`
`Jan. 9, 2007
`
`Sheet 1 of 30
`
`US 7,159,368 B2
`
`
`
`2.
`
`:
`
`S.
`
`afe
`
`Louisiana-Pacific Corporation, Exhibit 1054
`IPR of U.S. Pat. No. 8,474,197
`Page 3
`
`

`

`U.S. Patent
`
`Jan. 9, 2007
`
`Sheet 2 of 30
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`US 7,159,368 B2
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`
`
`FIG. 3
`(2%2f AAP
`
`Louisiana-Pacific Corporation, Exhibit 1054
`IPR of U.S. Pat. No. 8,474,197
`Page 4
`
`

`

`U.S. Patent
`
`Jan. 9, 2007
`
`Sheet 3 of 30
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`US 7,159,368 B2
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`S
`
`S
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`S
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`
`Louisiana-Pacific Corporation, Exhibit 1054
`IPR of U.S. Pat. No. 8,474,197
`Page 5
`
`

`

`U.S. Patent
`
`Jan. 9, 2007
`
`Sheet 4 of 30
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`US 7,159,368 B2
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`
`
`S
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`
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`
`Louisiana-Pacific Corporation, Exhibit 1054
`IPR of U.S. Pat. No. 8,474,197
`Page 6
`
`

`

`U.S. Patent
`
`Jan. 9, 2007
`
`Sheet 5 Of 30
`
`US 7,159,368 B2
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`
`
`s
`
`S/ S
`
`Louisiana-Pacific Corporation, Exhibit 1054
`IPR of U.S. Pat. No. 8,474,197
`Page 7
`
`

`

`U.S. Patent
`
`Jan. 9, 2007
`
`Sheet 6 of 30
`
`US 7,159,368 B2
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`Louisiana-Pacific Corporation, Exhibit 1054
`IPR of U.S. Pat. No. 8,474,197
`Page 8
`
`

`

`U.S. Patent
`
`Jan. 9, 2007
`
`Sheet 7 Of 30
`
`US 7,159,368 B2
`
`
`
`Louisiana-Pacific Corporation, Exhibit 1054
`IPR of U.S. Pat. No. 8,474,197
`Page 9
`
`

`

`U.S. Patent
`
`Jan. 9, 2007
`
`Sheet 8 of 30
`
`US 7,159,368 B2
`
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`Louisiana-Pacific Corporation, Exhibit 1054
`IPR of U.S. Pat. No. 8,474,197
`Page 10
`
`

`

`U.S. Patent
`
`Jan. 9, 2007
`
`Sheet 9 Of 30
`
`US 7,159,368 B2
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`Louisiana-Pacific Corporation, Exhibit 1054
`IPR of U.S. Pat. No. 8,474,197
`Page 11
`
`

`

`U.S. Patent
`
`Jan. 9, 2007
`
`Sheet 10 of 30
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`US 7,159,368 B2
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`Louisiana-Pacific Corporation, Exhibit 1054
`IPR of U.S. Pat. No. 8,474,197
`Page 12
`
`

`

`Louisiana-Pacific Corporation, Exhibit 1054
`IPR of U.S. Pat. No. 8,474,197
`Page 13
`
`

`

`U.S. Patent
`
`Jan. 9, 2007
`
`Sheet 12 of 30
`
`US 7,159,368 B2
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`Louisiana-Pacific Corporation, Exhibit 1054
`IPR of U.S. Pat. No. 8,474,197
`Page 14
`
`

`

`U.S. Patent
`
`Jan. 9, 2007
`
`Sheet 13 of 30
`
`US 7,159,368 B2
`
`N Ñ!!!!!!!4!!4!!!!
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`(7/6)
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`Louisiana-Pacific Corporation, Exhibit 1054
`IPR of U.S. Pat. No. 8,474,197
`Page 15
`
`

`

`U.S. Patent
`
`Jan. 9, 2007
`
`Sheet 14 of 30
`
`US 7,159,368 B2
`
`f5/2
`
`/52(2
`
`532
`
`/54(2
`
`7.252
`
`
`
`
`
`
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`BACKNG MATERAL
`
`LAMINATE RELEASE LINER
`TO ADHESIVE
`
`
`
`INSTALL PANELS
`
`
`
`CAULK BETWEEN
`PANELS
`
`
`
`APPLY TAPE TO JOINT
`
`FIG. 16
`
`
`
`
`
`
`
`Louisiana-Pacific Corporation, Exhibit 1054
`IPR of U.S. Pat. No. 8,474,197
`Page 16
`
`

`

`U.S. Patent
`
`Jan. 9, 2007
`
`Sheet 15 of 30
`
`US 7,159,368 B2
`
`
`
`
`
`
`
`
`
`APPLY ADHESVE TO
`EDGE OF PANEL
`
`LAMINATE RELEASE LINER
`TO ADHES WE
`
`
`
`INSTALL PANELS
`
`CAULK BETWEEN
`PANELS
`
`APPLY BACKING MATERAL
`TO ADHESIVE
`
`-
`
`FIG. f6
`
`fa/4
`
`
`
`Wa22
`
`Aa37
`
`WA41
`
`WAZ
`
`Louisiana-Pacific Corporation, Exhibit 1054
`IPR of U.S. Pat. No. 8,474,197
`Page 17
`
`

`

`U.S. Patent
`
`Jan. 9, 2007
`
`Sheet 16 of 30
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`US 7,159,368 B2
`
`
`
`
`
`
`
`
`
`
`
`INSTALL PANELS
`
`
`
`CAULK BETWEEN PANELS
`
`
`
`
`
`f7/2
`
`A22
`
`APPLY ADHESIVE TO
`EDGE OF PANEL OR TO BACKING MATERA
`
`f232
`
`APPLY BACKNG MATERAL OR BACKING
`MATERAL WITH ADHESIVE TO CENTER OF
`JOINT
`
`A74(7
`
`FIG. 1 7
`
`Louisiana-Pacific Corporation, Exhibit 1054
`IPR of U.S. Pat. No. 8,474,197
`Page 18
`
`

`

`U.S. Patent
`
`Jan. 9, 2007
`
`Sheet 17 Of 30
`
`US 7,159,368 B2
`
`APPLY ADHESVES TO 930 AND
`940 TO BACKING MATERAL
`
`
`
`LAMINATE RELEASE LINER
`TO ADHESIVE
`
`
`
`NSTALL PANELS
`
`
`
`CAULK BETWEEN
`PANELS
`
`
`
`
`
`
`
`
`
`
`
`
`
`fa/2
`
`WA,22
`
`232
`
`AS407
`
`APPLY TAPE TO JOINT
`
`A522
`
`FIG. 18
`
`Louisiana-Pacific Corporation, Exhibit 1054
`IPR of U.S. Pat. No. 8,474,197
`Page 19
`
`

`

`U.S. Patent
`
`Jan. 9, 2007
`
`Sheet 18 of 30
`
`US 7,159,368 B2
`
`
`
`
`
`
`
`
`
`
`
`APPLY ADHESIVES 930 AND
`940 TO BACKING MATERIAL
`
`LAMINAE RELEASE LNER
`TO ADHESVE
`
`
`
`NSTALL PANELS
`
`
`
`CAULK BETWEEN
`PANELS
`
`
`
`APPLY ADHESIVE 940 OR 930 TO
`BACKING MATERIAL OR TO PANEL
`
`
`
`
`
`
`
`W222
`
`/92
`
`/242
`
`/25/2
`
`APPLY TAPE TO JOINT
`
`W942
`
`FIG. 19
`
`Louisiana-Pacific Corporation, Exhibit 1054
`IPR of U.S. Pat. No. 8,474,197
`Page 20
`
`

`

`U.S. Patent
`
`Jan. 9, 2007
`
`Sheet 19 of 30
`
`US 7,159,368 B2
`
`APPLY ADHESIVE 930 TO
`BACKING MATERIAL OR TO EDGE OF PANEL
`
`
`
`LAMINATE RELEASE LNER TO
`ADHESIVE
`
`
`
`22/(2
`
`222
`
`22402
`
`
`
`
`
`
`
`
`
`
`
`
`
`27.67
`
`
`
`
`
`
`
`
`
`
`
`NSTALL PANELS
`
`
`
`CAULK BETWEEN
`PANELS
`
`
`
`APPLY TAPE TO JOINT
`
`FIG.20
`
`Louisiana-Pacific Corporation, Exhibit 1054
`IPR of U.S. Pat. No. 8,474,197
`Page 21
`
`

`

`U.S. Patent
`
`Jan. 9, 2007
`
`Sheet 20 of 30
`
`US 7,159,368 B2
`
`APPLY ADHESIVES 93O AND 940
`TO EDGE OF PANEL
`
`
`
`AMINATE RELEASE LNER TO
`ADHESIVE
`
`
`
`INSTALL PANELS
`
`
`
`CAULK BETWEEN
`PANELS
`
`
`
`
`
`
`
`APPLY BACKING MATERAL TO ADHESIVE
`
`FIG.21
`
`
`
`
`
`
`
`2//07
`
`2/32
`
`2/42
`
`2/52
`
`Louisiana-Pacific Corporation, Exhibit 1054
`IPR of U.S. Pat. No. 8,474,197
`Page 22
`
`

`

`U.S. Patent
`
`Jan. 9, 2007
`
`Sheet 21 of 30
`
`US 7,159,368 B2
`
`
`
`
`
`
`
`APPLY ADHESIVE 930 OR 940
`TO EDGE OF PANEL
`
`22/4
`
`LAMINATE RELEASE LINER TO
`ADHESIVE
`
`INSTALL PANES
`
`
`
`CAULK BETWEEN
`PANELS
`
`
`
`
`
`
`
`22402
`
`
`
`APPLY ADHESIVE 94.0 OR 930
`TO BACKING MATERAL OR PANEL
`
`292
`
`APPLY BACKING MAERAL
`TO ADHESIVE
`
`2252
`
`FIG.22
`
`Louisiana-Pacific Corporation, Exhibit 1054
`IPR of U.S. Pat. No. 8,474,197
`Page 23
`
`

`

`U.S. Patent
`
`Jan. 9, 2007
`
`Sheet 22 of 30
`
`US 7,159,368 B2
`
`
`
`
`
`INSTALL PANELS
`
`
`
`
`
`CAULK BETWEEN
`PANELS
`
`2/7
`
`222
`
`
`
`
`
`
`
`APPLY ADHESIVE 93O AND 94O TO
`PANE OR BACKING MATERIAL
`
`
`
`
`
`APPLY BACKING MATERIAL OR BACKING
`MATERAL WITH ADHESVE
`TO CENTER OF JOINT
`
`2467
`
`FIG.23
`
`Louisiana-Pacific Corporation, Exhibit 1054
`IPR of U.S. Pat. No. 8,474,197
`Page 24
`
`

`

`U.S. Patent
`
`Jan. 9, 2007
`
`Sheet 23 of 30
`
`US 7,159,368 B2
`
`
`
`24/7
`APPLY ADHESVE 930 OR
`940 TO BACKING MATERAL
`
`242
`APPLY ADHESIVE 940 OR 930 TO
`EDGE OF PANEL
`
`
`
`
`
`CAULK BETWEEN PANELS
`
`2.472
`
`FIG.24
`
`Louisiana-Pacific Corporation, Exhibit 1054
`IPR of U.S. Pat. No. 8,474,197
`Page 25
`
`

`

`U.S. Patent
`
`Jan. 9, 2007
`
`Sheet 24 of 30
`
`US 7,159,368 B2
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`
`
`6296
`
`62/6(796
`
`
`
`
`
`67076
`
`
`
`
`
`(7/60$6 02667% 6’(7/6
`
`92 "f)I, H.
`
`Louisiana-Pacific Corporation, Exhibit 1054
`IPR of U.S. Pat. No. 8,474,197
`Page 26
`
`

`

`U.S. Patent
`
`Jan. 9, 2007
`
`Sheet 25 of 30
`
`US 7,159,368 B2
`
`FABRICATE ELASTOMERC JOINT ACCORDING
`TO ANY OF METHODS 1-10
`
`26/4
`
`
`
`
`
`APPLY JOINT FILLER
`
`2522
`
`FIG.26
`
`Louisiana-Pacific Corporation, Exhibit 1054
`IPR of U.S. Pat. No. 8,474,197
`Page 27
`
`

`

`U.S. Patent
`
`Jan. 9, 2007
`
`Sheet 26 of 30
`
`US 7,159,368 B2
`
`s
`
`
`
`SSSSSSSSSSSSSNSS
`
`s
`
`s
`
`
`
`
`
`!----------4
`CNU s
`
`O
`
`s
`
`Louisiana-Pacific Corporation, Exhibit 1054
`IPR of U.S. Pat. No. 8,474,197
`Page 28
`
`

`

`U.S. Patent
`
`Jan. 9, 2007
`
`Sheet 27 of 30
`
`US 7,159,368 B2
`
`POSITION BUILDING PANELS
`ON FRAME
`
`FASTEN PANELS
`TO FRAME
`
`
`
`CAULK BETWEEN PANELS
`
`
`
`27/4
`
`252/7
`
`22
`
`
`
`
`
`
`
`ADHERE BACKING MATERAL
`
`254(2
`
`
`
`
`
`APPLY JOINT FILLER
`
`
`
`
`
`
`
`APPLY FINISH
`
`2522
`
`FIG.28
`
`Louisiana-Pacific Corporation, Exhibit 1054
`IPR of U.S. Pat. No. 8,474,197
`Page 29
`
`

`

`U.S. Patent
`
`Jan. 9, 2007
`
`Sheet 28 of 30
`
`US 7,159,368 B2
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`
`
`
`
`SEIT8W3SSW 000[\1S 690V 080|
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`
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`(S3HONI) NOI 103-30 13N
`
`Louisiana-Pacific Corporation, Exhibit 1054
`IPR of U.S. Pat. No. 8,474,197
`Page 30
`
`

`

`U.S. Patent
`
`Jan. 9,
`2007
`
`Sheet 29 Of 30
`
`US 7,159,368 B2
`
`47,6'
`
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`Louisiana-Pacific Corporation, Exhibit 1054
`IPR of U.S. Pat. No. 8,474,197
`Page 31
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`

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`U.S. Patent
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`Jan. 9, 2007
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`Sheet 30 of 30
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`US 7,159,368 B2
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`3/22 N
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`99/7 D.
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`97.407
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`2/7
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`257
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`FIC. 3 1A
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`/(207
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`9/4
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`22
`992
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`FIG 31 B
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`Louisiana-Pacific Corporation, Exhibit 1054
`IPR of U.S. Pat. No. 8,474,197
`Page 32
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`US 7,159,368 B2
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`1.
`PANELIZED WALL SYSTEM UTILIZING
`JOINT TAPE
`
`RELATED APPLICATIONS
`
`This application claims priority to U.S. Provisional Patent
`Application Ser. No. 60/333,967, filed Nov. 28, 2001, U.S.
`Provisional Patent Application Ser. No. 60/334,138, filed
`Nov. 28, 2001, and U.S. Provisional Patent Application Ser.
`No. 60/334,144, filed Nov. 28, 2001, the disclosures of
`which are incorporated by reference in their entireties.
`
`10
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`BACKGROUND OF THE INVENTION
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`this cracking, the joints are often covered with tape or filled
`with caulk. In many installations, both tape and caulk are
`used. In DEFS stucco applications over fiber cement, an
`alkali-resistant fiberglass mesh tape, 2" to 12" wide, joins the
`two adjacent fiber cement panels that are the substrate over
`which the stucco is applied.
`One problem with these types of joints is joint read,” a
`phenomenon in which the joint underlying the finish is
`visible. Joint read breaks the desired monolithic appearance
`of the finished wall. Joint read is a particular problem with
`fiber cement substrates because fiber-cement-panel faces
`absorb moisture from the finish coat faster than the taped
`joint. This differential moisture absorption makes the joint
`visible. In joints covered with tape, the step formed by the
`edge of the tape and the panel Surface can often be seen,
`especially with low-angle illumination. Cracks arising from
`the loss of adhesion or slipping at the edges of the tape cause
`another type of joint read.
`“Peaking' is another type of joint read and is caused by
`movement of the fiber cement panels. This movement causes
`the adhesive bond between the joint tape and the caulk joint
`to fail, causing the stucco to separate from the caulk. As a
`result, the stucco covering the joint floats higher or lower
`than the Surrounding area, giving the appearance of a peak.
`Peaking also results from the caulk shrinking during curing,
`pulling the adhered joint tape below the surface of the
`stucco. Peaking disrupts the monolithic appearance of the
`wall and destroys the integrity of both the stucco and the
`substrate.
`Another option is a thin joint sealing tape. These tapes,
`however, are often waterproof. Consequently, they do not
`absorb the stucco mix, resulting in poor adhesion between
`the stucco and the tape, which leads to Surface deformation.
`A more serious problem is cracking at the joints. Cracking
`not only disrupts the monolithic look of the finish, but also
`allows moisture to get behind the stucco and rot or corrode
`the wood or steel structural framing. Furthermore, these
`cracks are entry points for insects or fungi, which can
`damage the interior of the wall.
`Consequently, DEFS are rarely used where there is wide
`daily temperature variation especially when coupled with a
`high rate of wet/dry cycling. DEFS are also seldom used in
`the fast-growing manufactured housing market because of
`the additional stress placed on walls during transport. Solv
`ing the joint read and stucco-cracking problems could sig
`nificantly expand the market for DEFS stucco applications
`using fiber cement and other substrates. Not only could
`builders use fiber cement substrates and stucco in wetter
`climates, but also fiber cement Substrates and stucco use
`could be expanded to new markets such as manufactured
`housing and modular buildings.
`One strategy for preventing cracking of a DEFS coating
`at the panel joints is to construct joints from elastomeric
`materials. These elastomeric joints absorb the stress created
`by the differential panel movements. Such joints may be
`used with flexible, latex-based texture coatings, often called
`latex stucco or synthetic stucco. These finishes are able to
`move with the joint without cracking, which would greatly
`expand the market for DEFS applications.
`The effectiveness of such joints may be evaluated in test
`walls consisting of several panels assembled on a frame,
`constructed with the joint-to-be-tested. The test wall is
`finished with a DEFS coating and subjected to a racking test.
`The racking test applies an in-plane shear force to the test
`wall, resulting in relative panel movement, until the DEFS
`coating cracks. The distance of maximum deflection at
`which the finish cracks is a measure of performance of the
`
`15
`
`1. Field of the Invention
`The present application relates generally to walls made
`with building panels, and more particularly, to panelized
`wall systems with joints that are resistant to cracking con
`structed with an elastomeric joint tape.
`2. Description of the Related Art
`Every building tradition in the history of mankind has
`produced stuccowork. Examples of stuccowork range from
`the Aztec architecture of ancient Mexico to the architecture
`of North Africa and Spain. In modern times, stuccowork has
`been popular in residential construction since the 1920s,
`especially in dry, warm climates like the U.S. Southwest.
`Because of the many ways in which it can be treated, stucco
`remains a popular exterior finish for many building types.
`Since stucco is applied as a paste, it can be textured and will
`conform to almost any shape resulting in a Smooth, seamless
`wall of monolithic appearance and Sound structural integrity.
`In spite of its ongoing popularity, many builders resist
`using stucco as an exterior finish in framed construction
`because of the problems associated with applying stucco to
`exterior walls. Traditionally, a stucco coating is a thin paste
`composed of Portland cement, sand, lime, and water. Suc
`cessive layers of stucco paste are applied to a metal or plastic
`mesh fastened to the exterior of the wall. Stucco supported
`on framed construction is normally 7/8" thick and is applied
`in three applications: the first or scratch coat, the second or
`brown coat, and the third, a finish, colored, texture coating.
`Since each layer of stucco paste must dry and harden before
`the next is applied, it takes several days to finish a traditional
`stucco wall.
`While hundreds of thousands of new housing units are
`built every year, only a fraction of those units use stucco as
`an exterior finish. Stucco's susceptibility to moisture dam
`age, for example, limits its use in wet climates. Likewise,
`stresses caused by transporting stucco-finished transportable
`buildings prevent its use in the lucrative manufactured
`housing market.
`Another method of producing a textured or stucco look is
`a Direct-applied Exterior Finish System or DEFS. In DEFS,
`panels of a Substrate material are fastened to the framing
`followed by a finish texture coating. The texture coating may
`be applied as a single coat or in multiple thin coats, and often
`uses either a joint or full-wrap alkali-resistant fiberglass
`mesh to reinforce the coating against cracking. DEFS can be
`installed and finished in a much shorter time than traditional
`stucco, enabling shorter construction times.
`DEFS have not enjoyed a large share of the exterior
`market, however, because thin DEFS coatings, which are
`relatively brittle, are incompatible with the movements of
`wall panels. The substrate panels will invariably move with
`respect to each other from building settling, temperature
`variations, or moisture absorption. These movements can
`cause cracking of the finish at the panel joints. To prevent
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`US 7,159,368 B2
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`panel joints. For example, in order to pass the International
`Congress of Building Officials (ICBO) AC 59 "Acceptance
`Criteria for Direct-Applied Finishing Systems” (September
`1992), a test wall constructed according to the method
`described in ASTM E-72 (98) subjected to a racking load
`that causes the wall to deflect 1", does not develop any
`visible joint cracks.
`The polymeric adhesives used in joint tapes in DEFS tend
`to soften and lose holding power at 120° F., a temperature
`often achieved on the exterior vertical walls of a building
`exposed to full Summer Sun. Fiber cement building panels
`may become saturated with water in wet environments if
`installed improperly or if the finish layer fails. Many adhe
`sives bond poorly to wet substrates. The performance of
`adhesives used in manufacturing joint tapes for DEFS
`applications may be evaluated using the “180° peel test,” a
`well-known method of evaluating the adhesive strengths of
`tapes. The 180° peel test measures the force required to
`break the adhesion of a joint tape applied to two Substrates
`held at a 180° angle.
`U.S. Pat. No. 5,732,520 describes a method for forming a
`single-coat, synthetic-stucco-finished exterior wall. First,
`fiber cement wallboard panels are installed onto a building
`frame with the adjacent edges of the panels forming narrow
`gaps. Polyurethane caulk is applied to the gaps, and low
`profile fabric-backed joint tape is applied over the adjacent
`edges of the panels to cover the gaps and the caulk. A high
`build flexible resinous latex emulsion in next applied
`directly over the panels and adhesive tape to form a synthetic
`stucco finish. The moisture absorption properties of the
`fabric from which the tape is manufactured matches that of
`the wall panels. A stucco-finished joint constructed accord
`ing to this patent with 3"-wide joint tape slips and cracks at
`the edges when stretched 3–5 mm. The relative motion of
`adjacent 4"x8' cementitious boards under normal conditions
`is greater than 3–5 mm, however. While the joint tape
`described in U.S. Pat. No. 5,732,520 distributes the joint
`movement somewhat, the adhesive used in this tape is not
`Sufficiently strong to prevent the edges of tape from slipping
`under stress. Consequently, the edges of the tape slip,
`cracking the stucco coating. A wider tape, for example, a
`6"-wide tape, might better withstand the movement, but at
`an increased cost.
`Cracking may be also prevented by applying additional
`layers of stucco or a joint compound over the tape before
`applying the final coat of stucco. This method, however, is
`expensive, time consuming, and requires skilled workers.
`Moreover, this technique often fails to produce satisfactory
`results. Another method of preventing cracks is increasing
`the thickness of the stucco build. This method is also
`expensive and time consuming, however.
`
`SUMMARY OF THE INVENTION
`
`The present disclosure provides panelized wall systems
`constructed with an elastomeric joint tape and methods of
`their manufacture. The disclosed panelized wall systems
`have elastomeric joints that are resistant to cracking.
`Accordingly, a one embodiment provides a method of
`constructing a panelized wall system, comprising at least the
`steps of positioning at least two building panels over a
`frame, wherein each panel comprises a front Surface, a back
`Surface, and a plurality of edges, the back Surfaces of the
`panels are positioned over the frame, and the two panels are
`positioned adjacent to each other, forming a seam between
`the adjacent panels; fastening the building panels to the
`frame; forming an elastomeric joint, which comprises a joint
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`tape applied to the seam between the adjacent panels,
`wherein the joint tape comprises an adhesive applied to a
`face of a backing material; and applying an elastomeric
`finish over the joint tape and the panels; wherein the
`elastomeric joint does not crack when stretched by about
`6.6% or more.
`In a preferred embodiment, the building panels are fiber
`Cement.
`In a preferred embodiment, the adjacent panels are posi
`tioned with no gap between them. In another preferred
`embodiment, the adjacent panels are positioned with a gap
`between them. Preferably, the gap is about /s" wide.
`In a preferred embodiment, the elastomeric joint further
`comprises a caulk applied to the seam between the panels.
`Preferably, the caulk is a polyurethane caulk.
`In a preferred embodiment, the backing material is a
`fabric. Preferably, the backing material is from about
`0.0005" to about 0.04" thick. The fabric is preferably a
`non-woven polyester fabric or a polyamide mesh. Prefer
`ably, the backing material is about 3" wide.
`In a preferred embodiment, the elastomeric joint further
`comprises a ceramic putty applied over the backing material.
`In a preferred embodiment, the elastomeric joint further
`comprises an elastomeric joint filler ceramic putty applied
`over a ceramic putty.
`In an preferred embodiment, the elastomeric finish com
`prises an elastomeric primer and an elastomeric texture
`layer. In a preferred embodiment, the elastomeric finish is a
`texture coating.
`In a preferred embodiment, the frame is a wood frame. In
`a preferred embodiment, the frame comprises shear panels.
`In a preferred embodiment, the frame comprises a moisture
`barrier. In a preferred embodiment, the frame comprises a
`water break.
`Another embodiment provides a panelized wall system
`comprising: a frame; at least two building panels, wherein
`each panel comprises a front Surface, a back Surface, and a
`plurality of edges, the back Surfaces of the panels are
`positioned over the frame, the two panels are positioned
`adjacent to each other, forming a seam between the adjacent
`panels, and the panels are fastened to the frame; an elasto
`meric joint, which comprises a joint tape applied to the seam
`between the adjacent panels, wherein the joint tape com
`prises an adhesive applied to a face of a backing material;
`and an elastomeric finish applied over the joint tape and the
`panels; wherein the elastomeric joint does not crack when
`stretched by about 6.6% or more.
`In a preferred embodiment, the building panels are fiber
`Cement.
`In a preferred embodiment, the adjacent panels are posi
`tioned with no gap between them. In a preferred embodi
`ment, the adjacent panels are positioned with a gap between
`them. Preferably, the gap is about /s" wide.
`In a preferred embodiment, the elastomeric joint further
`comprises a caulk applied to the seam between the panels.
`Preferably, the caulk is a polyurethane caulk.
`In a preferred embodiment, the backing material is a
`fabric. Preferably, the backing material is from about
`0.0005" to about 0.04" thick. The fabric is preferably a
`non-woven polyester fabric or a polyamide mesh. Prefer
`ably, the backing material is about 3" wide.
`In a preferred embodiment, the elastomeric joint further
`comprises a ceramic putty applied over the backing material.
`In a preferred embodiment, the elastomeric joint further
`comprises an elastomeric joint filler ceramic putty applied
`over a ceramic putty.
`
`Louisiana-Pacific Corporation, Exhibit 1054
`IPR of U.S. Pat. No. 8,474,197
`Page 34
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`

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`5
`In a preferred embodiment, the elastomeric finish com
`prises an elastomeric primer and an elastomeric texture
`layer. In a preferred embodiment, the elastomeric finish is a
`texture coating.
`In a preferred embodiment, the frame is a wood frame. In
`an twenty-fourth preferred embodiment, the frame com
`prises shear panels. In a preferred embodiment, the frame
`comprises a moisture barrier. In a preferred embodiment, the
`frame comprises a water break.
`A further embodiment provides a method of constructing
`a panelized wall system comprising: positioning at least two
`building panels over a frame, wherein each panel comprises
`a front Surface, a back Surface, and a plurality of edges, the
`back Surfaces of the panels are positioned over the frame,
`and the two panels are positioned adjacent to each other,
`forming a seam between the adjacent panels; fastening the
`panels to the frame; forming an elastomeric joint, wherein
`the elastomeric joint comprises a backing material adhered
`over the seam between the adjacent panels, and applying an
`elastomeric finish to the panelized wall system; wherein the
`elastomeric finish does not develop any visible cracks under
`a racking load that causes the panelized wall system to
`deflect 1" according to the test method described in ASTM
`E-72 (98).
`In a preferred embodiment, the building panels are fiber
`Cement.
`In a preferred embodiment, the adjacent panels are posi
`tioned with no gap between them. In a preferred embodi
`ment, the adjacent panels are positioned with a gap between
`them. Preferably, the gap is about /s" wide.
`In a preferred embodiment, the elastomeric joint further
`comprises a caulk applied to the seam between the panels.
`Preferably, the caulk is a polyurethane caulk.
`In a preferred embodiment, the backing material is a
`fabric. Preferably, the backing material is from about
`0.0005" to about 0.04" thick. The fabric is preferably a
`non-woven polyester fabric or a polyamide mesh. Prefer
`ably, the backing material is about 3" wide.
`In a preferred embodiment, the elastomeric joint further
`comprises a ceramic putty applied over the backing material.
`In a preferred embodiment, the elastomeric joint further
`comprises an elastomeric joint filler applied over the
`ceramic putty.
`In a preferred embodiment, the elastomeric finish com
`prises an elastomeric primer and an elastomeric texture
`45
`layer. Preferably, the elastomeric finish is a texture coating.
`In a preferred embodiment, the frame is a wood frame. In
`a preferred embodiment, the frame comprises shear panels.
`In a preferred embodiment, the frame comprises a moisture
`barrier. In a preferred embodiment, the frame comprises a
`water break.
`Another embodiment provides a panelized wall system
`comprising a frame; at least two building panels, wherein
`each panel comprises a front Surface, a back Surface, and a
`plurality of edges, the back Surfaces of the panels positioned
`over the frame, the two panels are positioned adjacent to
`each other, forming a seam between the adjacent panels, and
`the panels are fastened to the frame; an elastomeric joint
`comprising a backing material adhered over the seam
`between the adjacent panels; and an elastomeric finish
`applied to the panelized wall system; wherein the elasto
`meric finish does not develop any visible cracks under a
`racking load that causes the panelized wall system to deflect
`1" according to the test method described in ASTM E-72
`(98).
`In a preferred embodiment, the building panels are fiber
`Cement.
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`US 7,159,368 B2
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`In a preferred embodiment, the adjacent panels are posi
`tioned with no gap between them. In a thirty-ninth preferred
`embodiment, the adjacent panels are positioned with a gap
`between them. Preferably, the gap is about /s" wide.
`In a preferred embodiment, the elastomeric joint further
`comprises a caulk applied to the seam between the panels.
`Preferably, the caulk is a polyurethane caulk.
`In a preferred embodiment, the backing material is a
`fabric. Preferably, the backing material is from about
`0.0005" to about 0.04" thick. The fabric is preferably a
`non-woven polyester fabric or a polyamide mesh. Prefer
`ably, the backing material is about 3" wide.
`In a preferred embodiment, the elastomeric joint further
`comprises a ceramic putty applied over the backing material.
`In a preferred embodiment, the elastomeric joint further
`comprises an elastomeric joint filler applied over the
`ceramic putty.
`In a preferred embodiment, the elastomeric finish com
`prises an elastomeric primer and an elastomeric texture
`layer. Preferably, the elastomeric finish is a texture coatin